Method of storing and shipping a gasket

ABSTRACT

A method of storing a flexible polygonal article, such as a gasket, is provided. Initially, a storage device is selected. Next, an article constructed of a plurality of interconnected elongated side members is selected. Each of the plurality of side members have an internal wall and an external wall attached perpendicular thereto. Next, a support member is selected from the plurality of side members and moved above the storage device. The storage device includes a storage shelf having a support channel with a horizontal and vertical surface. The support member is then placed in the support channel such that the internal wall of the support member is supported on the horizontal surface. Finally, at least a portion of the first external wall is magnetically engaged to at least a portion of the vertical surface, thereby supporting the flexible article on the storage device.

FIELD OF THE INVENTION

The present invention relates to a method of storing and shipping a flexible gasket, and more particularly, to a method of storing and shipping a flexible gasket having a compressible structure.

BACKGROUND OF THE INVENTION

Flexible plastic gaskets made of rubber, vinyl or other similar materials are used in many applications to provide an effective seal between doors and door frames, windows and window frames, and other such devices. These gaskets often include a soft compression bulb or cell which helps to increase the seal and thus the energy efficiency of the gasket. These types of gaskets are often used on refrigerator doors and other home and commercial appliance products sold in relatively high volumes. In such applications, the gaskets, and in particular the cell has a contoured or non-planar configuration which cooperates with a complementary contoured surface on the appliance for improving the seal therebetween. Thus, it is desirable to ship and store such seals on a manner which maintains the cross-sectional configuration of the cell.

Gasket manufacturers must store and ship these gaskets in high volumes. Hence, racks have been developed to carry a large group of gaskets. The racks typically include a frame supporting a shelf, from which the gaskets are hung. One such rack design includes a shelf having a flat surface from which the gaskets are simply hung by a selected side on the flat surface. Another design includes a shelf having a contoured surface. The surface is typically constructed of vacuum molded plastic to define a plurality of channels. The channels are not typically formed to accommodate a specific gasket or cell configuration. Nonetheless, the gaskets are hung from the shelf by placing a selected side in a channel. A problem with both of the above-described shelf designs and methods of storing gaskets is that the weight of the gasket tends to deform the gasket supported on the shelf, particularly the soft compression bulb or cell.

SUMMARY OF THE INVENTION

A method of storing and shipping a flexible polygonal article, such as an energy efficient gasket, is provided. Initially, a storage device is selected. Next, an article constructed of a plurality of interconnected elongated side members is selected. Each of the plurality of side members have an internal wall and an external wall attached perpendicular thereto. Next, a support member is selected from the plurality of side members. The support member is then moved above the storage device. The storage device includes a storage shelf having a plurality of support channels. The support channels include a horizontal surface and a vertical surface. The support member is then placed in a support channel such that the internal wall of the support member is supported on the horizontal surface. Finally, a portion of the external wall of the article is magnetically engaged to a portion of the vertical surface of the support channel, thereby supporting the article in the channel.

A gasket shipped and stored in accordance with the present invention will maintain the cross-section of the cell and remain substantially undeformed during shipping and storage. As such, the gasket can provide the energy efficient fit as designed for a given application. The present invention, and in particular the magnetic engagement of the seal with the rack has the added benefit of facilitating the proper placement of the gasket within the rack at the end of the gasket manufacturing process.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is a perspective view of an exemplary embodiment of a device for storing and shipping a flexible polygonal article in accordance with the present invention;

FIG. 2 is a cross-sectional view of an exemplary storage shelf of the device taken along line II-II of FIG. 1 including a side member of a flexible polygonal article supported therein; and

FIG. 3 is a flowchart depicting an exemplary method of storing a flexible polygonal article in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the scope of the invention, its application, or its uses.

With reference to FIG. 1, an exemplary embodiment of a device 10 in accordance with the present invention is described. The device 10 includes a base frame 12, a support frame 14, and a storage shelf 16. The base frame 12 includes four support staffs 18 welded to a peripheral frame 20 and a pair of longitudinal bars 22. Each of the support staffs 18 include a male portion 24 and a female portion 26. The peripheral frame 20 includes a pair of receiving tubes 28 adapted to receive a transporting device, such as a pair of forks on a fork lift. As presently preferred, the support frame 14 includes an inverted A-frame 30 welded to a crossbar 32, which is supported on the longitudinal bars 22 of the base frame 12. The support shelf 16 is fixedly supported on the support frame 14 and includes a plurality of channels 34, each adapted to receive and support a flexible polygonal article such as a gasket 52 as hereinafter described.

With reference to FIG. 2, the storage shelf 16 is described in detail. As mentioned above, the storage shelf 16 includes a plurality of transverse channels 34 defined by adjacent walls members 36 extending from a base 38. More particularly, the wall members 36 have a base flange 40 generally parallel to the base 38. The base flange 40 is secured to the base 38 by any suitable means such as adhesive, welding or mechanical fasteners. A support flange 42 extends upwardly from the base flange 40. The configuration of the support flange 42 is such that it provides clearance for the contour of the gasket. For example, as shown in FIG. 2, the support flange 42 steps upwardly away from the base flange 40. In this manner, the support flange provides a step 44 on one side thereof and a plate fastening portion 46 is formed on an opposite side thereof. An engagement element 48 is secured to the plate fastening portion 46 by any suitable means such as adhesive or mechanical fasteners. In an exemplary embodiment, the base 38 and the wall members 36 are constructed of a vacuum-formed plastic. As presently preferred, the engagement element 48 is a ferrous metal plate; however, it should be appreciated that in an alternative embodiment, the metal plate may be magnetized.

The relationship between the base 38, the wall member 36, horizontal surface 36, and the step 44 defines a channel 34 which is shaped to engagingly support a gasket 52 without deforming or distorting the gasket 52 during storage and shipping. Before describing the method of storing and shipping a gasket in accordance with the present invention, it is beneficial to describe the configuration of a typical gasket 52. With reference to FIG. 2, gasket 52 is of the type having a compression bulb or cell 54 defined by the walls 56, 58, 60, 62 thereof. The gasket 52 also includes a permanent magnet 64 formed in one wall 56 and a dart 64 providing means to secure the gasket 52 to an appliance extends from another wall 58 of the gasket 52. The gasket 52 may also include sealing flanges 66 extending from compression cell 54. From the foregoing description, one skilled in the art will recognize that the shape and details of the gasket 52 are determined by the design of the appliance.

With reference to FIGS. 1, 2 and 3 an exemplary method of storing the gasket 52 in accordance with the present invention is described. Initially, a rack or storage device 10 for storing a plurality of gaskets 52 is selected at block 100. Next, the gasket 52 is selected at block 102 to be hung on the rack 10. Next, the channel 34 within which the gasket 52 will hang, is identified at block by 104. The gasket 52 is positioned over channel 34 at block 106. The gasket 52 is placed into the channel 34 such that the dart 64 rests on step 44 and the permanent magnet 64 is magnetically engaged to the engagement element 48 at block 108. As seen in FIG. 2, the gasket 52 is diagonally supported across the channel 34 in a manner which allows the gasket 52 to freely hang therein. This engagement prevents deformation of the walls 58, 60, 62, 64, and particularly wall 56, from collapsing or distorting under the force of gravity acting on the gasket 52. Thus, the cell 62 formed within the gasket 52 maintains its original geometry through the physical rigors of shipping and prolonged storage.

The present invention provides a method of shipping a plurality of gaskets is provided. Accordingly, the above method further includes engaging the peripheral frame 20 of the base frame 12 with a transporting device (not shown) such as a fork lift, crane or other lifting device. In an exemplary embodiment, a pair of forks on a fork lift are received in the pair of support tubes 28 in the peripheral frame 20. The fork lift is then free to lift and move the rack 10 freely about. The shipping method further includes stacking multiple racks 10 upon each other prior to shipping the plurality of gaskets 50. Accordingly, a second rack (substantially identical to rack 10) is selected subsequent to placing a set of gaskets 52 on the first rack 10. Once the second rack is fully loaded, it is engaged by a transporting device (not shown), such as a fork lift, as described above. The second rack is then lifted above and placed on the first rack 10. The plurality of female portions 26 on the vertical support staffs 18 of the second rack receive the plurality of male portions 24 on the vertical support staffs 18 of the first rack 10, thereby securely stacking the two racks. It should be appreciated that while the method described herein only includes two racks being stacked, a method including any number of racks being stacked is intended to be within the scope of the present invention.

The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. 

1. A storage and shipping rack for a flexible gasket of the type having a storage shelf supported on a support frame, the storage shelf comprising a plurality of storage channels, each of said plurality of storage channels including an elongated horizontal surface, and an elongated vertical surface extending substantially perpendicular from said horizontal surface, a portion of said elongated vertical surface having a ferrous metal element defining a vertical magnetic engagement surface.
 2. The rack of claim 1 wherein said base frame includes a plurality of vertical support staffs interconnected by a peripheral frame having a set of receiving tubes.
 3. The rack of claim 2 wherein said plurality of vertical support staffs each include a male portion on one of a top and bottom end and a female portion on the other of said top and bottom end.
 4. The rack of claim 1 wherein said support frame includes an inverted A-frame structure attached to a cross bar disposed between said base frame and said storage shelf.
 5. The rack of claim 1 wherein each of said plurality of channels further include a step portion disposed on said horizontal surface on a side of said channel opposite from said vertical surface.
 6. The rack of claim 1 where said horizontal surface is a vacuum formed plastic component.
 7. The rack of claim 1 wherein each of said plurality of storage channels being defined by a pair of ribs, each rib having said elongated vertical surface formed thereon.
 8. The rack of claim 7 wherein said ferrous metal element is a steel plate having an edge received in a groove formed in said channel adjacent said vertical surface.
 9. The rack of claim 8 wherein said steel plate extends above said elongated vertical surface formed on a first of said pair of ribs.
 10. The rack of claim 9 wherein a second of said pair of ribs defines a step portion on a side of said channel opposite from said elongated vertical surface.
 11. A method of storing and shipping a flexible gasket comprising: providing a flexible gasket having a compressible bulb portion and a magnetic element disposed in a first surface thereof; positioning said flexible gasket on a storage shelf having a plurality of support channels formed therein; locating said compression bulb in one of said plurality of support channels; and magnetically engaging said magnetic element to an elongated vertical surface adjacent said one of said plurality of support channels.
 12. The method of claim 11 further comprising the step of positioning a dart extending from a second surface of said flexible gasket on a step adjacent said one of said plurality of support channels.
 13. The method of claim 11 further comprising the steps of: positioning additional flexible gaskets in each of said plurality of support channels formed in said storage shelf; locating said compression bulb of said additional flexible gaskets in one of said plurality of support channels; and magnetically engaging said magnetic element of said additional flexible gaskets to an elongated vertical surface adjacent said one of said plurality of support channels, whereby each of said plurality of support channels is provided with a flexible gasket.
 14. The method of claim 11 wherein at least a portion of said vertical surface comprises a ferro-metallic element.
 15. A method of transporting flexible gaskets comprising: locating a first storage rack in a loading position, said first storage rack including a storage shelf having a support channel with a horizontal surface and a vertical surface extending therefrom and having a ferrous metal element; selecting an gasket having a plurality of elongated side members attached at their ends to form a polygon, each of said plurality of side members having a first wall portion with a magnetic element formed therein and a second wall portion; positioning said flexible gasket above said first storage rack; placing said flexible gasket in said support channel such that said first wall is supported on said horizontal surface and at least a portion of said second wall magnetically engages with said ferrous metal element, thereby supporting said flexible gasket on said first storage rack; and transporting said first storage rack to a location remote from said loading position.
 16. The method of claim 15 wherein the step of placing said flexible gasket in one of said plurality of channels further includes placing a dart extending from a second wall of said flexible gasket onto a step portion of said storage shelf.
 17. The method of claim 15 further comprising the step of: locating a second storage rack in said loading position, said second storage rack including a storage shelf having a support channel with a horizontal surface and a vertical surface extending therefrom and having a ferrous metal element; selecting an gasket having a plurality of elongated side members attached at their ends to form a polygon, each of said plurality of side members having a first wall portion with a magnetic element formed therein and a second wall portion; positioning said flexible gasket above said second storage rack; placing said flexible gasket in said support channel such that said first wall is supported on said horizontal surface and at least a portion of said second wall magnetically engages with said ferrous metal element, thereby supporting said flexible gasket on said second storage rack; transporting said second storage rack to said location remote; and stacking said second storage rack on top of said first storage rack. 